CARVALHO DOS SANTOS, Jorge (Rua Prof. Urbano de Moura 244 - 6.º, -358 Gaia, P-4400, PT)
053584
CLAIMS
l. A Modular structure of prefabricated concrete, for example, applied in the construction of prefabricated houses and removable structures, characterized in that it comprises a set of elements that form the walls of a construction as prefabricated concrete panels with a top plan view in form of an L shape, wherein these elements:
- are constituted by expanded clay and concrete;
- are divided into three parts according to their height/position; the upper and lower parts that are thicker and operate as sets of beams throughout the length of the L; and a less thicker central part which thereby creates an air box (2) with a plaque of interior finishing (3) ;
- receive settlement points (15) in mortar, directly applied in the ground where the inferior part of the element seats;
- an inferior beam (7) of reinforcement throughout the inferior part of the element and a superior beam (10) of reinforcement throughout the superior part of the element;
- have a welded wire mesh (8) continuum in the upper/lower part of the element, around the superior
(10) and inferior (7) set of beams throughout the length of the L shape, and throughout the central part of the element.
2. Modular structure according to claim 1 characterized in that a construction is may comprise more than one set of elements in a vertical line, being the construction height a multiple of the element height. 3584
3. Modular structure according to claim 2 characterized in that the union procedure between the upper and lower elements of a wall is made through a male-female connection (1) between the upper zone of each element and the inferior zone of the element to overlap.
4. Modular structure according to claim 1 characterized in that the doors and windows are done and prepared in advance while shaping the piece, or by cutting the element to the extent of the installation that it will be set.
5. Construction method of prefabricated houses and removable structures, according to claim 1 characterized in that it comprises the following steps:
- outlining the periphery and the interior of the construction;
- stabilizing the placement height through points of settlement (15) in mortar, whose placing is established and executed during the assembly of the 1st row of elements;
- performing the interior pavement concrete pouring, having as a reference plane the settlement face of the lower beam;
- before or after pouring the floor with concrete, it is possible to place more rows of elements, according to the intended height;
- insulating the joints between elements, the faying surface between juxtaposed elements and the roof with a sealant film and silicone caulking;
- linking the juxtaposed elements being ensured by the use of steel bars (16) attached with two or more threaded rods; - accomplishing the roof using any traditional method.
- placing the water and electricity nets as well as the internal insulation in the air box (2) of the wall in any position according to the intended functionality. |
DESCRIPTION
"MODULAR STRUCTURE OF PREFABRICATED CONCRETE AND RESPECTIVE PRODUCTION METHOD OF A HABITATION"
Technical field of the Invention
The present invention refers to an auto-stabilized and leveled prefabricated modular structure.
The present invention allows an immediate self sustainability of the part-wall, conferring in simultaneous the definition of a space-dividing wall at the time of the construction.
The present invention can be applied in the construction of several spaces, as for example: prefabricated houses and removable structures, among others. Therefore, to build such constructions it is not necessary to fall back on the delayed works of a normal construction such as: foundations; low shoes; pillars; and beams. This directly results in economy from the non-utilization of these elements in the prefabricated/traditional construction thereby reducing the construction time.
Invention Background
The pre-fabrication of concrete structures was developed as part of the tradition for metallic and wooden structures, which are, by its very nature, prefabricated. This applies to the construction of temporary structures, having a considerable evolution in terms of assembly and construction techniques.
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Over the past few years an increase in the use of prefabricated structures has been observed, finding structural solutions with beams, pillars or prefabricated houses .
Therefore, the present invention is a basic structural solution, functional and economic that considerably reduces the constructions work process.
There are already some buildings using prefabricated concrete structures. Although these structures considerably reduce the construction time, they however do not exempt the previous preparation of the building area such as the foundation execution for positioning of pillars, the beams and the lintel beams.
Document US2007119111 describes a prefabricated house construction process. Regarding the present request they are based on a metal structure where the panels that form the walls are fixed.
Document DE19702860 describes a wooden house construction process, where the panels are assembled to form the exterior and interior walls and roof through corner parts. This is a modular construction but it does not have the strength and resistance of a reinforced concrete house with an insulation system of the present invention.
The prefabricated concrete structures according to this invention, for its characteristics of rigidity and stability, allow the simplification of the previous said works adding a reduced construction time.
Brief Description of the Drawings
For easier understanding of the invention the attached figures, which represent the preferential invent accomplishments, do not intend, to limit the present invention.
Fig. 1 illustrates a top plan view of a modular prefabricated concrete structure implementation in the production of a dwelling.
Fig. 2 illustrates a top plan view of the element top.
Fig. 3 illustrates a partial cross-section view of the element taken through lines A—B of fig.2.
Fig. 4 illustrates a cross-section view of the element taken through lines C--D of fig.3.
Fig. 5 illustrates a partial cross-section view of the wall element with the armor skeleton, taken through lines A—B of fig.2.
Fig. 6 illustrates a perspective view of the base element of the modular prefabricated concrete structure.
Detailed Description of the Invention
The invention is a prefabricated cellular concrete element that allows eliminating foundations, pillars and beam executions, which are usually built separately during the execution of a construction. The solution to this problem is in the elements shape.
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In a top plan view the elements present an L shape (i.e. lying on ground) , which for itself defines a space/dividing area simultaneous allowing the element auto-stabilization. Thus the implementation of these elements, gives the possibility of modulating any construction, introducing with its placing-shape-size, external and internal dimensions, to the criterion and step of the executant/user/designer (see fig.l) .
Looking at a section, we see that the wall integrates in the upper/lower part of its elements, a concrete thickness increase which in practice translates in a beam body shape to grant stiffness, allowing to also integrate insulation materials in the air box of the element (see fig.3)
Each element is divided in three parts according to its height: the upper/lower parts that are thicker; and a less thick central part establishing an air box (2) with the plaque of interior finishing (3) , which will serve for placement of infrastructures and insulation materials.
The structure described in the present invention, can easily be leveled on surfaces/irregular soil, through: use of 3 settlement points (15) leveled in mortar, directly applied in the area matching the place where the element seats on ground (see fig.3 and fig.6); or through a previously executed concrete slab (5) .
To make the union between the top and bottom elements of a wall they contain a male-female connection type (1) between the upper part of each element and the bottom part of the element to overlap (see fig.3) .
The structure rigidity along with its lightness is given by the lower and upper element reinforcement beams and are further strengthened with an armor of welded wire mesh (8) specially folded in order to combine the mesh stiffness with the beam's section shape (see fig.5) . The welded wire mesh (8) is placed in a continuous way in the upper/lower part of the element, around the upper (10) and lower (7) beams throughout the length of the L and along the central part of the element (9) .
The acoustic, thermal and waterproof properties, stem from the materials that it is made of, and the combination of the panel hollow form with insulation materials, being the internal coating surface, a Pladur type material.
Doors and windows can be made and prepared in advance while shaping the piece, or by cutting the element to the extent of the installation that it will be set in. The walls exterior finishing could be any coating product.
For example, to form a wall of approximately 10 feet high it' s necessary to vertically overlap two elements with 5 feet high. The capability to stack the elements is possible due to an easy setting between the lower part of the top element and upper part of the element underneath it through a male-female connection type (1) (see fig.3) . It is obtained by stacking, internal heights with multiple times the height of the piece.
The construction versatility is optimized with use of symmetrical elements (right and left parts) , which of course will be assembled in order to achieve a better outcome from the desired configuration.
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The complementarily of the internal or external walls can be achieved by cutting of a portion of these elements, thus getting an identical finishing in the whole built area.
This method of construction therefore comprises the following:
outline the periphery and the interior of the construction in compliance with a predetermined project; stabilize the placement: through settlement points (15) in mortar that are placed on the ground under each one of these elements (see fig.6); or through a concrete pavement (5) . after the well placed elements form the intended implantation, it may be possible to pour the interior with concrete, having as a reference plane the settlement face of the lower beam (see fig.3 and fig.5 and fig.6) . Before or after pouring the interior with concrete, place a second or third row of elements till the desired height is achieved, (e.g. a multiple height of 5 feet) as well as, ground and walls infrastructure placement. The joints between elements, faying surface between juxtaposed elements and roof should be insulated with a sealant film and silicone caulking. The union between the elements is ensured by the male-female connection type (1) with silicone caulking and the use of steel bars (16) with 2 or more threaded rods each, attached to the upper and lower beams of the stacked elements (see fig.3 and fig.6); the roof consists of: sandwich panel elements, fixed by screwing with the help of plastic anchors on the superior beam of the top elements, still being able
to apply linking screws on the internal partition walls (i.e. if any); or any other type of traditional roofing, the water and electricity nets as well as the internal insulation could be freely installed in the air box (2) of the wall in any position in accordance with the intended functionality.
It must stay clear that the achievements of the present modular structure of prefabricated concrete and its own house production method, previously described, are simply, possible implementation samples, merely set for a clear understanding of the invention principles. Various revisions and modifications can be made to the preferred embodiments disclosed herein without departing from the spirit and scope of the invention. All such revisions and variations must be enclosed in the scope of the present invention and protected by the following claims.
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